CN102607969A - Device and method for testing forming limit of sheet material in three-dimensional stress state - Google Patents
Device and method for testing forming limit of sheet material in three-dimensional stress state Download PDFInfo
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Abstract
三维应力状态下板材成形极限测试装置及方法,涉及一种板材成形极限测试所使用的装置及方法。针对板材三维应力状态下成形极限难于测试及法向压力对成形极限的影响难于评估问题,装置包括上模和下模。测试时依次向下模内注入流体介质、放置板材试样、施加合模力、向上模内注入流体介质、控制上模和下模内的压力进行加压变形的过程。根据测得的圆形或正方形网格变形前后的数据计算金属板材试样的破裂应变ε1=Ln[d1-d/d]和ε2=Ln[d-d2/d];改变型腔椭圆截面的长短轴比,获得多组不同极限应变数据点,分别以ε1和ε2为横坐标和纵坐标,将所获得的数据点进行连接或者拟合,获得在某一法向压力条件下的三维应力状态下的板材成形极限曲线;用于评估三维应力状态中法向应力对成形极限的影响。
The invention relates to a device and a method for testing the forming limit of a plate under a three-dimensional stress state, relating to a device and a method used for the forming limit test of a plate. Aiming at the difficulty of testing the forming limit under the three-dimensional stress state of the plate and the difficulty of evaluating the influence of the normal pressure on the forming limit, the device includes an upper die and a lower die. During the test, the fluid medium is injected into the lower mold, the plate sample is placed, the mold clamping force is applied, the fluid medium is injected into the upper mold, and the pressure in the upper mold and the lower mold is controlled for pressurized deformation. Calculate the rupture strain ε 1 =Ln[d 1 -d/d] and ε 2 =Ln[dd 2 /d] of the sheet metal sample according to the measured data before and after the deformation of the circular or square grid; change the cavity ellipse The ratio of the long and short axis of the cross-section is used to obtain multiple sets of data points of different ultimate strains, and the abscissa and ordinate of ε 1 and ε 2 are respectively used to connect or fit the obtained data points to obtain The sheet forming limit curve under the three-dimensional stress state; used to evaluate the influence of the normal stress on the forming limit in the three-dimensional stress state.
Description
技术领域 technical field
本发明涉及一种测试板材在三维应力状态下成形极限的装置及方法。The invention relates to a device and method for testing the forming limit of a plate under a three-dimensional stress state.
背景技术 Background technique
成形极限是板材成形领域中重要的性能指标和工艺参数,反映了板材在塑性失稳前所能取得的最大变形程度。为确定板材拉伸失稳的成形极限,目前从理论和实验等方面提出了许多研究与评价方法。其中,Nakazima试验法是目前常用的方法,其实质是半球刚性凸模胀形试验。通过丝网印刷方法在试样表面印制圆形网格,改变试样宽度和试件与凸模间的润滑进行半球刚性凸模胀形实验,试样破裂后,网格由圆形变成椭圆形,测量靠近破裂点位置的椭圆形网格长短轴的大小,计算长短轴的应变值,获得数据点,即可绘制出成形极限曲线FLC。这种试验方法获得的成形极限值接近工业生产中板材普通冲压的实际情况,符合二维应力条件下的成形。The forming limit is an important performance index and process parameter in the field of sheet metal forming, reflecting the maximum deformation degree of the sheet before plastic instability. In order to determine the forming limit of sheet tensile instability, many research and evaluation methods have been proposed from the aspects of theory and experiment. Among them, the Nakazima test method is a commonly used method at present, and its essence is a hemispherical rigid punch bulge test. Print a circular grid on the surface of the sample by screen printing, change the width of the sample and the lubrication between the test piece and the punch to carry out the hemispherical rigid punch bulge experiment, after the sample breaks, the grid changes from a circle to a Ellipse, measure the size of the major and minor axes of the elliptical grid near the rupture point, calculate the strain value of the major and minor axes, obtain data points, and then draw the forming limit curve FLC. The forming limit value obtained by this test method is close to the actual situation of ordinary stamping of plates in industrial production, and conforms to the forming under two-dimensional stress conditions.
近年来,以流体为传力介质的液压成形技术以其工艺柔性高、制模简单、成形零件质量好等优点,日益得到广泛的重视,能够克服普通冲压成形方式的不足,尤其适合在一道工序内成形变形量大的复杂板材零件。对于板材正反加压液压成形及管材内外加压液压成形,坯料在高压流体压力作用下,坯料变形往往处于三维应力状态下,Nakazima试验法已经不能符合三维应力状态下坯料变形的实际情况。In recent years, the hydroforming technology using fluid as the force transmission medium has been paid more and more attention due to its advantages of high process flexibility, simple mold making, and good quality of formed parts. It can overcome the shortcomings of ordinary stamping methods, and is especially suitable for one process Complex plate parts with large amount of internal forming deformation. For the positive and negative pressure hydroforming of sheet metal and the internal and external pressure hydroforming of pipes, the deformation of the blank is often in a three-dimensional stress state under the action of high-pressure fluid pressure. The Nakazima test method can no longer meet the actual situation of the blank deformation under the three-dimensional stress state.
发明内容 Contents of the invention
针对目前测量成形极限的Nakazima试验法不能符合三维应力状态下坯料变形的实际情况,本发明提供一种三维应力状态下板材成形极限测试装置及方法,使用该方法及装置可获得板材在不同三维应力状态下的成形极限,满足实际应用。In view of the fact that the current Nakazima test method for measuring the forming limit cannot meet the actual situation of blank deformation under the three-dimensional stress state, the present invention provides a test device and method for the forming limit of the sheet metal under the three-dimensional stress state. The forming limit under the state meets the practical application.
本发明为解决上述技术问题采取的技术方案是:The technical scheme that the present invention takes for solving the problems of the technologies described above is:
本发明所述的三维应力状态下板材成形极限测试装置包括上模和下模,所述上模的型腔的内表面为椭圆柱面,所述上模的顶端上设有与型腔相通的上模液体注入孔;下模上设有贯通下模的下模液体注入孔,上模液体注入孔的轴线、下模液体注入孔的轴线、型腔沿长度方向的中心线三者同轴设置,上模和下模合模后通过密封圈进行密封。The plate forming limit test device under the three-dimensional stress state of the present invention includes an upper mold and a lower mold, the inner surface of the cavity of the upper mold is an elliptical cylinder, and the top of the upper mold is provided with a hole that communicates with the cavity. The upper mold liquid injection hole; the lower mold is provided with a lower mold liquid injection hole through the lower mold, the axis of the upper mold liquid injection hole, the axis of the lower mold liquid injection hole, and the center line of the cavity along the length direction are arranged coaxially , After the upper mold and the lower mold are closed, they are sealed by a sealing ring.
利用上述测试装置的三维应力状态下板材成形极限测试方法,所述测试方法是按照以下步骤实现的:Using the test method of the plate forming limit test method under the three-dimensional stress state of the above test device, the test method is realized according to the following steps:
步骤一、准备多套上述测试装置,各个测试装置中型腔的椭圆形截面的长短轴比值各不相同,各个椭圆形截面的长短轴比值在1~2.5范围内均匀选取;
步骤二、制作金属板材试样:利用电蚀腐方式在圆形金属板材试样的上表面制作呈矩阵排布的多个圆形或正方形凹痕,使圆形金属板材试样的上表面为矩阵排布的圆形网格或的正方形网格状;测量呈矩阵排布的圆形或正方形凹痕的直径d或正方形凹痕的边长d;
步骤三、夹紧金属板材试样:将带有印制上述网格的金属板材试样放置在下模的上表面上且使网格表面朝上,压力机滑块带动上模下行接触所述金属板材试样,施加合模力、压紧金属板材试样;
步骤四、双向压力加载:在位于金属板材试样上方的上模液体注入孔内注入流体介质,在位于金属板材试样下方的下模液体注入孔内注入流体介质;在金属板材试样上表面施加法向压力P2;在金属板材试样下表面施加胀形压力P1;并使法向压力P2与胀形压力P1相等;
步骤五:胀形实验:增加下模液体注入孔内部压力P1,板材试样发生胀形变形,直至试样发生破裂;破裂后,裂纹附近排布的圆形网格变成椭圆形网格,排布的正方形网格变成长方形网格;卸载型腔和下模液体注入孔内部的压力及合模力,压力机滑块带动上模回程;Step 5: Bulging experiment: Increase the internal pressure P 1 of the liquid injection hole of the lower mold, and the plate sample undergoes bulging deformation until the sample ruptures; after the rupture, the circular grids arranged near the cracks become elliptical grids , the arranged square grid becomes a rectangular grid; the pressure and clamping force inside the cavity and the liquid injection hole of the lower mold are unloaded, and the slider of the press drives the upper mold to return;
步骤六:测量金属板材试样上变形后的网格:将金属板材试样卸下,测量金属板材试样上的破裂位置附近椭圆长轴长度d1和短轴长度d2,或测量金属板材试样上的破裂位置附近长方形长边长度d1和短边长度d2;Step 6: Measuring the deformed grid on the sheet metal sample: remove the sheet metal sample, measure the major axis length d 1 and the minor axis length d 2 of the ellipse near the rupture position on the sheet metal sample, or measure the sheet metal The length d 1 of the long side and the length d 2 of the short side of the rectangle near the rupture position on the sample;
步骤七:根据测得的圆形或正方形网格变形前后的数据计算金属板材试样的破裂应变ε1=Ln[d1-d/d]和ε2=Ln[d-d2/d],即可获得一组应变数据点;Step 7: Calculate the rupture strain ε 1 =Ln[d 1 -d/d] and ε 2 =Ln[dd 2 /d] of the sheet metal sample according to the measured data before and after the deformation of the circular or square grid, namely A set of strain data points can be obtained;
改变型腔椭圆截面的长短轴比,重复上述步骤,即可获得多组不同极限应变数据点,分别以ε1和ε2为横坐标和纵坐标,绘制数据点,将所获得的数据点进行连接或者拟合,即可获得在某一法向压力P2条件下的三维应力状态下的板材成形极限曲线;Change the long-short axis ratio of the elliptical section of the cavity and repeat the above steps to obtain multiple sets of data points with different ultimate strains, draw the data points with ε 1 and ε 2 as the abscissa and ordinate respectively, and carry out the obtained data points By connecting or fitting, the sheet metal forming limit curve under a three-dimensional stress state under a certain normal pressure P2 can be obtained;
法向压力P2取不同的值可得一组具有一定上下平移量的板材成形极限曲线束。Different values of normal pressure P 2 can be used to obtain a set of sheet metal forming limit curve bundles with a certain amount of up and down translation.
本发明具有以下优点:The present invention has the following advantages:
1、采用本发明所述装置对板材试样进行成形极限曲线测试,方法简单,易于实现,可替代Nakazima试验法,为成形极限测定提供一种新方法。1. Using the device of the present invention to test the forming limit curve of the plate sample is simple and easy to implement. It can replace the Nakazima test method and provide a new method for the determination of the forming limit.
2、对板材试样施加双面的法向压力,使板材处于法向Z方向和胀形引起的平面X、Y方向的三维应力状态,可获得不同法向压力条件下的成形极限曲线,方便评估三维应力状态中法向应力对成形极限的影响。使用本发明所述装置及方法既可替代Nakazima试验法测定板材胀形成形极限,也可评估三维应力状态中法向应力对成形极限的影响。2. Apply double-sided normal pressure to the plate sample, so that the plate is in the normal Z direction and the three-dimensional stress state of the plane X, Y direction caused by bulging, and the forming limit curve under different normal pressure conditions can be obtained, which is convenient Evaluate the effect of normal stress on the forming limit in a 3D stress state. The device and method of the invention can replace the Nakazima test method to determine the forming limit of sheet material bulging, and can also evaluate the influence of the normal stress in the three-dimensional stress state on the forming limit.
附图说明 Description of drawings
图1是本发明所述的三维应力状态下板材成形极限测试装置的结构示意图;图2是图1的A-A剖面图(椭圆柱面的截面图,2a为短轴、2b为长轴),图3印有圆形网格的板材试样图,图4印有正方形网格的板材试样图;图5利用本发明方法可得到的板材成形极限曲线图。Fig. 1 is the structural representation of sheet material forming limit test device under the three-dimensional stress state of the present invention; Fig. 2 is the A-A sectional view of Fig. 1 (the sectional view of elliptic cylinder, 2a is minor axis, 2b is major axis), Fig. 3 is a diagram of a plate sample printed with a circular grid, Fig. 4 is a diagram of a plate sample printed with a square grid; Fig. 5 is a curve diagram of the forming limit of a plate that can be obtained by using the method of the present invention.
具体实施方式 Detailed ways
具体实施方式一:如图1~5所示,本实施方式所述的三维应力状态下板材成形极限测试装置包括上模1和下模4,所述上模1的型腔1-2的内表面为椭圆柱面,所述上模1的顶端上设有与型腔1-2相通的上模液体注入孔1-1;下模4上设有贯通下模4的下模液体注入孔4-1,上模液体注入孔1-1的轴线、下模液体注入孔4-1的轴线、型腔1-2沿长度方向的中心线三者同轴设置,上模1和下模4合模后通过密封圈3进行密封。上模1和下模4合模后,下模液体注入孔4-1与型腔1-2的开口部相通,所述上模1与压力机滑块连接;所述下模4与压力机工作台连接、固定;上模1和下模4内均设置密封圈3。Specific Embodiment 1: As shown in Figures 1 to 5, the sheet metal forming limit test device under a three-dimensional stress state according to this embodiment includes an
具体实施方式二:如图1~5所示,本实施方式所述的利用具体实施方式一所述测试装置的三维应力状态下板材成形极限测试方法是按照以下步骤实现的:Specific embodiment 2: As shown in Figures 1 to 5, the test method for sheet metal forming limit under the three-dimensional stress state using the test device described in
步骤一、准备多套权利要求1所述测试装置,各个测试装置中型腔1-2的椭圆形截面的长短轴比值各不相同,各个椭圆形截面的长短轴比值在1~2.5范围内均匀选取;
步骤二、制作金属板材试样:利用电蚀腐方式在圆形金属板材试样的上表面制作呈矩阵排布的多个圆形或正方形凹痕,使圆形金属板材试样的上表面为矩阵排布的圆形网格或的正方形网格状;测量呈矩阵排布的圆形或正方形凹痕的直径d或正方形凹痕的边长d;
在本步骤中,在金属板材试样的上表面涂敷一层光致抗蚀剂,然后透过掩模对金属板材试样上表面的光致抗蚀剂层进行选择性曝光,即把要印制的网格轮廓部分进行曝光,所述腐蚀的网格轮廓为以矩阵排布的圆形网格轮廓或以矩阵排布的正方形网格轮廓,用金属腐蚀液对已曝光部分的矩阵排布的圆形网格轮廓内部或矩阵排布的正方形网格轮廓内部进行腐蚀,矩阵排布的圆形网格或矩阵排布的正方形网格即可印制到金属板材试样的上表面上,测量矩阵排布的圆形网格的直径d(或者正方形网格边长),从而得到金属板材试样;In this step, a layer of photoresist is coated on the upper surface of the metal plate sample, and then the photoresist layer on the upper surface of the metal plate sample is selectively exposed through a mask, that is, the Part of the printed grid outline is exposed, and the etched grid outline is a circular grid outline arranged in a matrix or a square grid outline arranged in a matrix. Corrosion is carried out inside the circular grid outline of the cloth or the square grid outline arranged in a matrix, and the circular grid arranged in a matrix or the square grid arranged in a matrix can be printed on the upper surface of the metal sheet sample , measure the diameter d (or the side length of the square grid) of the circular grid arranged in matrix, so as to obtain the sheet metal sample;
步骤三、夹紧金属板材试样:将带有印制上述网格的金属板材试样2放置在下模4的上表面上且使网格表面朝上,压力机滑块带动上模1下行接触所述金属板材试样2,施加合模力、压紧金属板材试样2;
步骤四、双向压力加载:在位于金属板材试样2上方的上模液体注入孔1-1内注入流体介质,在位于金属板材试样2下方的下模液体注入孔4-1内注入流体介质;在金属板材试样2上表面施加法向压力P2;在金属板材试样2下表面施加胀形压力P1;并使法向压力P2与胀形压力P1相等;
步骤五:胀形实验:增加下模液体注入孔4-1内部压力P1(胀形压力P1),板材试样发生胀形变形,直至试样发生破裂;破裂后,裂纹附近排布的圆形网格变成椭圆形网格,排布的正方形网格变成长方形网格;卸载型腔1-2和下模液体注入孔4-1内部的压力及合模力,压力机滑块带动上模1回程;Step 5: Bulging experiment: increase the internal pressure P 1 (bulging pressure P 1 ) of the liquid injection hole 4-1 of the lower mold, and the plate sample undergoes bulging deformation until the sample ruptures; The circular grid becomes an elliptical grid, and the arranged square grid becomes a rectangular grid; the pressure and clamping force inside the cavity 1-2 and the liquid injection hole 4-1 of the lower mold are unloaded, and the press slider Drive the
步骤六:测量金属板材试样上变形后的网格:将金属板材试样2卸下,测量金属板材试样上的破裂位置附近椭圆长轴长度d1和短轴长度d2,或测量金属板材试样上的破裂位置附近长方形长边长度d1和短边长度d2;Step 6: Measure the deformed grid on the metal sheet sample: remove the
步骤七:根据测得的圆形或正方形网格变形前后的数据计算金属板材试样的破裂应变ε1=Ln[d1-d/d]和ε2=Ln[d-d2/d],即可获得一组应变数据点;Step 7: Calculate the rupture strain ε 1 =Ln[d 1 -d/d] and ε 2 =Ln[dd 2 /d] of the sheet metal sample according to the measured data before and after the deformation of the circular or square grid, namely A set of strain data points can be obtained;
改变型腔1-2椭圆截面的长短轴比,重复上述步骤,即可获得多组不同极限应变数据点,分别以ε1和ε2为横坐标和纵坐标,绘制数据点,将所获得的数据点进行连接或者拟合,即可获得在某一法向压力P2条件下的三维应力状态下的板材成形极限曲线;Change the ratio of the major and minor axes of the elliptical section of the cavity 1-2, and repeat the above steps to obtain multiple sets of data points with different ultimate strains. The data points are plotted with ε 1 and ε 2 as the abscissa and ordinate respectively, and the obtained By connecting or fitting the data points, the sheet metal forming limit curve under a three-dimensional stress state under a certain normal pressure P2 can be obtained;
法向压力P2取不同的值可得一组具有一定上下平移量的板材成形极限曲线束。Different values of normal pressure P 2 can be used to obtain a set of sheet metal forming limit curve bundles with a certain amount of up and down translation.
如图5所示,每条曲线上的点的坐标为(ε1,ε2)。As shown in Fig. 5, the coordinates of the points on each curve are (ε 1 , ε 2 ).
具体实施方式三:本实施方式在步骤一中准备七套权利要求1所述测试装置,各个测试装置中型腔1-2的椭圆形截面的长短轴比值分别为1、1.2、1.4、1.6、1.8、2.0和2.5,短轴长为50mm,长轴分别为50mm、60mm、70mm、80mm、90mm、100mm和125mm;在步骤二中,制作的圆形金属板材试样的直径为200mm。其它步骤与具体实施方式二相同。Specific embodiment three: In this embodiment, seven sets of test devices according to
流体介质容腔1-2(型腔1-2)内的压力P2起到施加法向压力、建立三维应力状态的作用,流体介质容腔(下模液体注入孔4-1)内的压力P1使试样发生胀形。该方法既可替代Nakazima试验法测定胀形极限,也可评估三维应力状态中法向应力对成形极限的影响。The pressure P2 in the fluid medium cavity 1-2 (cavity 1-2) plays the role of applying normal pressure and establishing a three-dimensional stress state, and the pressure in the fluid medium cavity (lower mold liquid injection hole 4-1) P 1 makes the sample bulge. This method can not only replace the Nakazima test method to determine the bulging limit, but also evaluate the influence of the normal stress on the forming limit in the three-dimensional stress state.
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